Michael GreenmanExecutive Director

Efficient Enterprises: Powering American Industry

Industry Examples

Cannon House Office BuildingNovember 17, 2009

Examples from Industry

GlassSteelMetalcastingChallenges for the future

Traditional Furnace

“Siemens” Furnace – “Float Glass”

Submerged Combustion Melter

1- Batch charger; 2- Refractory lining; 3- Water cooled panels;4- Melting zone; 5- Exhaust; 6- Melt outlet; 7- Submerged oxygas burners; 8- Batch material (sloped pocket of batch)

Submerged Combustion Melter

Primary Features Metal Box – Watercooled Walls Oxy-Fuel Burners

Low Capital Cost (-60%)

Low Footprint (6-8 X Pull Rate for equivalent area)

High Efficiency, Low Emissions (20% more efficient) High Flexibility

4 hours hot to cold or cold to hot New products, markets, business models

IMM – first commercial Application Water Glass

Indiana Melting and Manufacturing, LaPorte, IN

SCM Partners

Corning Owens Corning PPG Johns Manville Schott Gas Technology Institute (GTI) GMIC DOE, NYSERDA, GRI funding

Cross-Cutting Applications

Steel Industry – Electric Arc Furnace Dust Aluminum – Spent Aluminum Potliner Forest Products – Black Liquor Gasification Cement – Blended and Specialty Cements Chemicals – Sodium Silicate Waste Vitrification – Portable – Move to

location Mineral Wool – Original Application Nuclear Waste Stabilization – Increase Cost-

Effectiveness

Examples from Industry

GlassSteel

Laser Contouring of Basic Oxygen Furnace – Fast Laser Contouring of Basic Oxygen Furnace – Fast Measurement of the Converter for Process ControlMeasurement of the Converter for Process Control

Examples from Industry

GlassSteelMetalcasting

Energy-Saving Melting and Revert Reduction Technology (E-SMARRT)

CANMET

Oak Ridge National Lab

Energy -SMARRT R&D Project Team

Thirteen foremost metalcasting R&D organizations

Energy-SMARRT Industrial Partners

93 E-SMARRT Industry Cost Share Partners

• Most are early adopters

Cost share through October 2009: $10,642,487 (125% of government provided funds)

Melting Efficiency Improvement Projects

Results: Trials for new “sandwich” ladle lining

resulted in energy consumption reduction by 30-60%

The addition of chemical energy through use of a supersonic oxyfuel system resulted in a decrease of 20 kwh/ton

Benchmarking the efficiency of holding furnaces for aluminum die casting operations and disseminating results through industry workshops

Develop new melting technologies and processes to improve energy efficiency of melting processes in foundry operations

Examples from Industry

GlassSteelMetalcastingChallenges for the Future

Glass - Strength

Strength of Glass

Condition of Glass lb/Square Inch

Surfaces ground and sandblasted < 4,000 Pressed Articles 3,000 – 8,000 Blown Ware:

Hot Iron Molds 4,000 – 9,000 Paste Molds 5,000 – 1,500 10,000 Inner Surfaces 15,000 – 40,000

Drawn tubing or rod 6,000 – 15,000 Window Glass 8,000 – 20,000

LCD (0.65 mm) ~45,000 Annealed fibers

Annealed 10,000 – 40,000 Freshly drawn 30,000 – 400,000 Gorilla Glass (Samsung – Mobile Phone) 100,000-200,000 Telecommunications Fiber >100,000

Possible New Markets for Ultra-Strong Glass

Ultra-Thin film Solar CellsEnergy StorageGlass Balloon SatellitesStructural Supports

Ultra-Strong Glass

Hexagonal Close Packing of Buoyant Glass Spheres

Insland Anchored to Sea Floor

Power Plants Used to Produce Fresh Water as well as Store Energy

Commercial Real Estate

Wildlife Refuges for Plants and Wildlife

Examples from Industry

GlassSteelMetalcastingChallenges for the Future

Glass – StrengthAll Energy Intensive Industries:

Waste Heat Recovery

Waste Heat Recovery

Largest “low hanging fruit”Pre-Heat raw materials (batch/cullet)Steam for facility useDistributed Generation“Glass Plant (or other) as Power Plant”

Examples from Industry

GlassSteelMetalcastingChallenges for the Future

Glass – StrengthAll Energy Intensive Industry:

Waste Heat RecoveryCommercial Implementation

“Everyone wants to be first to be second”

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